Method of assembling mufflers



Jan. 16, H s ELL METHOD OF ASSEMBLING MUFFLERS F iled Feb 1938 ,6 "x? 6J 3 a r I ;oooo6 o 6 0 0000000 00000 0 o 0 0000000 9,. L 00 0 o o 00000000 0000000 0 0 0000 3 I 0000000 0 m 0 00000 i 0000000 0 o o ovooo0000000 qq q Patented Jan. 16, 1940 UNlTED STATES PATENT OFFICE METHODOF ASSEMBLING MUFFLERS Herbert s. Powell, Utica, N. Y.

Application February 3, 1938, Serial No. 188,587

2 Claims.

The invention relates generally to the art of manufacturing internalcombustion engine exhaust quieting mufilers and has for an object toprovide a novel and advantageous method of assembling the parts embodiedin such mufilers.

I Mufilers of the character stated comprise an outer casing or shell,end closures or headers, and intermediate baffle elements usuallyassembled with one or both headers and designed to control the directionof movement and the rapidity of expansion of the exhaust gases so as toreduce to a minimum noise incident to the exhausting of the gases. It iscustomary to assemble the outer shell and the intermediate elements andheader separately, and then to push the header and baiile assembly intothe outer shell. This method of assembly is objectionable because of theamount of time necessary to be consumed in effecting the assembly, andthe difiiculties encountered in attempting to obtain an assembly proofagainst vibration and rattling.

The invention therefore seeks to provide a novel method of assemblingmufllers which includes the steps of first assembling the baffle orballle and header unit, then placing the shell forming sheeting aboutthe unit with the edges thereof overlapped to form a longitudinal seam,then subjecting the shell and the included unit to pressure so as totightly grip the unit within the shell and hold the edges in overlappedrelation, and while maintaining said pressure, securing said seam topermanently retain the as sembly of shell and the encased bafile andheader unit.

36 Another object of the invention is to include in the method, thesteps of securing the shell seam by welding, and thereafterweld-securing the headers at the respective ends of the muffler.

With the above and other objects in view that 49 will hereinafterappear, the nature of the invention will be more clearly understood byfollowing the description, the appended claims, and the several viewsillustrated in the accompanying drawing.

In the drawing:

Fig. 1 is a face view illustrating the step of separate assembly of thebaflie or ballle and header unit;

50 Fig. 2 is an end view illustrating the step of placing the shellsheeting about the baffle or bafile and header unit;

Fig. 3 is a vertical cross section illustrating the step of subjectingthe shell and the included 55 battle or baille and header unit topressure;

Fig. 4 is. a fragmentary vertical longitudinal section taken on the line4-4 on Fig. 3;

Fig. 5 is a view similar to Fig. 3, and illustrates the step of securingthe shell seam by welding;

lg. 6 is a detail perspective view diagram- 6 matically illustrating thestep of weld-securing the headers in the shell.

My improved method may be practiced in the assembly of mufflers ofvarious types and shapes, and with the aid of various forms ofapparatus. 10

In Fig. 1 of the drawing I have generally indicated the step ofassembling the bafile or baflle and header unit. This unit may be formedand fabricated or assembled in any suitable manner, and since theparticular manner of assembling this unit, in itself, forms no part ofmy present invention I have deemed it sufficient to illustrate the unitin the assembled state. The particular unit shown includes intermediatewall members 5 in which are supported the gas course directing 20 orbattle tubes 6, and the unit may include one or both headers or endclosure members 1 through which project the inlet and discharge pipes 8and 9.

After the unit exemplified in Fig. 1 has been 25 assembled, a sheet ofmetal is placed about it, as shown in Fig. 2, with the longitudinaledges of the sheet overlapping as at It], thus forming a unit encasingshell I l. While I have herein disclosed a muffler oval in transversesection, it 80 is to be understood that mulilers which are round orotherwise shaped may be assembled by my improved method.

When the muffler has been temporarily assembled as shown in Fig. 2, itis placed in a press 86 of suitable form and herein disclosed ascomprising a stationary jaw l2 and a movable jaw 13, and subjected toexternal pressure so as to tightly grip the bailie or baflle and headerunit Within the shell H and hold the edges ill in 40 overlappedrelation. An air cylinder I4 or other suitable mechanical means may beemployed to force the jaws I2 and I3 together for applying and holdingthe desired pressure. See Fig. 3.

While the baille or bafile and header unit is 5 being held tightlygripped within the shell II, by application of external pressure asabove described, the seam formed by the overlapped edges Ill ispermanently secured, preferably by welding, as indicated at iii. Forthis purpose the jaw !2 may be equipped with equidistantly spacedopenings It through which the weld stick or electrode diagrammaticallyindicated at H can be applied to the seam. See Figs. 3 and 4. It ispreferred that the securing of the seam shall be 2.0-

by the jaws i2 and t3, the assembling of the mufiler can be completed byweld-securing the headers or end closures 'l as indicated at I8 in Fig.6.

By practicing the improved method hereinde scribed, mufiiers can beassembled more rapidly,

more economically, and more efliciently than by the previously knownmethods in which the shell and baflle and header units were individuallyassembled and the inner units forced into the encasing shells. I

What I claim is: I i

l. The herein described method of assembling mufflers which comprises,forming a vbafile and header unit including two headers and at least onewall therebetween, placing sheeting about the two headers and wall toform an encasing shell with edges of the sheeting overlapped to form afull length longitudinal seam, subjecting the shell and the encased unitto pressure-f such degree as to tightly grip the unit within the shelland hold the edges in overlapped relation and to retain the aforesaidwall inplace without the necessity of welding same to the shell toprevent rattling of the wall in use, while maintaining said pressureapplication, weld-securing said seam to permanently retain the assemblyof the shell and encased unit, and welding said headers and shelltogether.

2. The herein described method of assembling inufilers which comprises,forming a bafile and header unit including two headers and at least onewall therebetween, placing sheeting about the "two headers and wall toform a full length longitudinal seam, subjecting the shell and theencased unit to pressure of such degree as to tightly grip the unitwithin the shell and hold the edges in overlapped relation and to retainthe aforesaid wall in place without the necessity of welding same to theshell to prevent rattling of the wall in use, while maintaining saidpressure application, Weld-securing said seam to permanently retain theassembly of the shell and encased unit, relaxing said pressureapplication, and thereafter Weld-securing the shell to the unit headerportions.

HERBERT S POWELL.

